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  • C07C29/132—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
  • C07C29/136—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH
  • C07C29/14—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of a —CHO group
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  • B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • B01J23/85—Chromium, molybdenum or tungsten
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  • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
  • B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • B01J23/85—Chromium, molybdenum or tungsten
  • B01J23/86—Chromium
  • B01J23/866—Nickel and chromium
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
  • B01J35/31—Density
  • B01J35/32—Bulk density
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
  • B01J35/64—Pore diameter
  • B01J35/657—Pore diameter larger than 1000 nm
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
  • B01J37/0018—Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
  • B01J37/0063—Granulating
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  • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
  • B01J8/008—Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction
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  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
  • C07C29/17—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by hydrogenation of carbon-to-carbon double or triple bonds
  • C07C29/172—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by hydrogenation of carbon-to-carbon double or triple bonds with the obtention of a fully saturated alcohol
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • B01J23/24—Chromium, molybdenum or tungsten
  • B01J23/26—Chromium
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  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • B01J23/24—Chromium, molybdenum or tungsten
  • B01J23/28—Molybdenum
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  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
  • B01J23/74—Iron group metals
  • B01J23/745—Iron
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/02—Impregnation, coating or precipitation
  • B01J37/0215—Coating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/02—Impregnation, coating or precipitation
  • B01J37/0215—Coating
  • B01J37/0217—Pretreatment of the substrate before coating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/02—Impregnation, coating or precipitation
  • B01J37/0215—Coating
  • B01J37/0225—Coating of metal substrates
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/08—Heat treatment
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C31/00—Saturated compounds having hydroxy or O-metal groups bound to acyclic carbon atoms
  • C07C31/18—Polyhydroxylic acyclic alcohols
  • C07C31/20—Dihydroxylic alcohols
  • C07C31/207—1,4-Butanediol; 1,3-Butanediol; 1,2-Butanediol; 2,3-Butanediol

Definitions

• the present invention relates to a process for producing 1,4-butanediol (BDO) and a catalyst for use in this process.
• 1,4-butanediol itself is mainly used in the textile, leather, food and pharmaceutical industries. As an intermediate, it is mainly used for the production of thermoplastic polyesters.
• BDO is a synthetic precursor in the preparation of several important chemical intermediates and solvents such as tetrahydrofuran (THF), ⁇ -butyrolactone or pyrrolidine.
• BDO 2-butyne-1,4-diol
• a one-step variant of this process is typically carried out at 80-160 ° C under a pressure of about 300 bar in a fixed bed reactor.
• a two-stage hydrogenation of BYD is also known, wherein the first stage, in which mainly 2-butene-1,4-diol (BED) is prepared, is carried out under a lower pressure of about 40 bar. In the second stage, BED is converted to BDO at 300 bar.
• BED 2-butene-1,4-diol
• Other processes based on acetylene as the main raw material for the production of BDO are also known.
• allyl alcohol can be converted by hydroformylation with synthesis gas (CO + H 2 ) to 4-hydroxybutanal (4-HBA) and further hydrogenated to BDO, wherein the two steps can take place simultaneously.
• synthesis gas CO + H 2
• 4-hydroxybutanal 4-HBA
• BDO 4-hydroxybutanal
• Further information about the BDO is available for Example in Ullmann's Encyclopedia of Industrial Chemistry, chapter “butanediols, butenediol, and butynediol” published online on 15.06.2000 , DOI: 10.1002 / 14356007.a04_455.
• the "Raney type" nickel catalysts commonly used for hydrogenation are generally prepared by forming an at least one binary metal alloy, usually comprising aluminum (Al) and nickel (Ni), and then dissolving out aluminum. Descriptions of such methods are given, for example, in the publications US 1628190 A . US 1915473 A . US 2139602 . US 2977327 disclosed.
• US 2967893 A discloses the use of a slurry of a powdered copper-promoted nickel catalyst for the hydrogenation of BYD to BDO.
• the activation of a precursor of the catalyst can be carried out separately or in situ in a hydrogenation reactor for the production of BDO, such as in EP 0340970 A2 and DE 2004611 A1 described.
• DE 2004611 A discloses a continuous process for the preparation of BDO by the hydrogenation of an aqueous solution of BYD.
• a fixed bed of granular, apertured nickel-aluminum catalyst is used, which can be removed by removing about 5 to 30% of the Aluminum has been activated from a substantially about 35 to 60 wt .-% nickel and about 40 to 65 wt .-% of aluminum existing nickel-aluminum alloy.
• the catalyst particles forming the fixed bed have particle sizes in the range from about 2 cm to 1.4 mm, preferably from about 1 cm to 2 mm.
• EP 0807464 A1 discloses a process for the catalytic hydrogenation of hydroxy aldehydes and cyclic hydroxy ethers on a modified Raney nickel catalyst containing 40-98 wt% Ni, 1-50 wt% Al, 0.05-15 wt% Fe and optionally 0, 05-10 wt% of at least one metal selected from the group consisting of Cr, Mo, W, Co, Mn and Ti.
• This catalyst may be of the powder type when the reaction is carried out in a slurry bed reactor.
• the in EP 0807464 A1 be disclosed granulate type catalyst when the reaction is carried out in a fixed bed reactor, as in DE 2004611 A ,
• EP 1833778 B1 discloses a process for the hydrogenation of 4-hydroxybutyraldehyde (HBA) to 1,4-butanediol (BDO) and / or 2-methyl-3-hydroxypropionaldehyde (HMPA) to 2-methyl-1,3-propanediol, wherein an aqueous solution of HBA and / or HMPA is contacted with hydrogen in an adiabatic hydrogenation zone by contact with a fixed bed of a hydrogenation catalyst which is a molybdenum activated nickel catalyst.
• HBA 4-hydroxybutyraldehyde
• BDO 1,4-butanediol
• HMPA 2-methyl-3-hydroxypropionaldehyde
• the disadvantage of the currently known process for the preparation of BDO is in industrial use in the extremely high demand for nickel, which is used in these methods as a hydrogenation catalyst of the Raney type.
• granule-type nickel catalysts are commonly employed which are introduced into the reactor as an unactivated precursor and activated in situ by leaching out aluminum. These catalysts usually have bulk densities of more than 1.5 kg / L, so that at reactor fillings of 5 to 50 m 3 of catalyst, as they are necessary in the usual activity of these catalysts to obtain sufficient product yields, between 8 and 100 tons of nickel be used.
• Nickel is one of the rarest metals, with a mass fraction of around 0.01% in the earth's envelope. Availability in economically accessible resources is limited. In addition, the worldwide demand for nickel for technical applications, for example in the electronics and materials sector, is steadily rising.
• a further underlying object was the provision of catalysts by means of which the corresponding chemical reactions can be conducted to BDO with sufficient yields and selectivities under industrially relevant process conditions.
• the process according to the invention takes place in the presence of water. Preference is given to using from 1 to 70% by weight aqueous solutions of BYD or 4-HBA as starting material.
• the educt solutions brought into contact with the activated nickel catalyst may contain up to 60% by weight of the target product BDO. This applies in particular if the hydrogenation reactors in which the process according to the invention is carried out are circulation reactors.
• the process according to the invention is preferably carried out at a hydrogen pressure in the range from 10 to 350 bar.
• the hydrogenation of 4-HBA is preferably carried out at 10 to 110 bar, more preferably 40 to 100 bar.
• the hydrogenation of BYD to BDO is preferably carried out at a hydrogen pressure in the range from 50 to 350 bar, more preferably from 75 to 320 bar and most preferably from 100 to 300 bar.
• the process of the invention can be carried out at temperatures of 50 to 250 ° C.
• the hydrogenation of 4-HBA to BDO is preferably carried out at 50 to 200 ° C, more preferably at 50 to 150 ° C and most preferably in the temperature range from 50 to 100 ° C.
• the hydrogenation of BYD to BDO is preferably carried out in a temperature range from 50 to 150 ° C, more preferably at 70 to 140 ° C and most preferably in the temperature range between 80 and 135 ° C.
• the process according to the invention for the hydrogenation of BYD or 4-HBA can be carried out batchwise or continuously. In discontinuous operation (batch operation) in a stirred tank reactor, the catalyst used can be stirred loosely in the reaction mixture. After completion of the reaction, the catalyst can be separated off from the reaction mixture, for example by filtration, removal / pumping off of the supernatant reaction solution or in another manner known to the person skilled in the art.
• a holding device is used for the catalyst used.
• the catalyst is preferably arranged in a holding device close to the stirring shaft such that a flow of the reaction mixture through the catalyst bed introduced into the holding device is produced by the stirrer.
• This embodiment has opposite to the loose, i. unfixed use of the catalyst has the advantage that a subsequent separation of the product mixture from the catalyst in an additional process step is not needed.
• the inventive method is carried out continuously in a fixed bed reactor, for example in a trickle bed or sump reactor, in a bubble column or in another type of reactor known to the art. All of these reactor types can be operated in a "once through” mode in which the reactants (feed) are introduced into the reactor and the product mixture is discharged after the reaction. Alternatively, a portion of the product mixture from the reactor can be recycled back to the reaction zone (recycle stream). In such a circulation (recycling operation), the weight ratio of feed to circulation stream is 0.025 to 0.25, preferably 0.05 to 0.15, particularly preferably 0.05 to 0.1.
• the implementation of BYD to BDO can be carried out in one or two stages.
• the one-stage reaction of the hydrogenation of BYD to BDO is preferably carried out continuously, wherein the catalyst is present as a fixed bed in an adiabatically operated reactor.
• the temperature in the reactor inlet is then preferably in the range of 80 to 100 ° C, the temperature in the reactor outlet between 110-150 ° C.
• a temperature preferably results in the reaction zone in which the hydrogenation reaction proceeds to the BDO, which is in a range between 110 and 135 ° C.
• a two-stage temperature control is preferably selected.
• the temperature in the stirred tank is maintained at the beginning of the reaction in the range of 90 to 105 ° C, so that butyne-1,4-diol is reacted with hydrogen at least partially to butene-1,4-diol.
• An ideal hold time for the most complete conversion of BYD to butene-1,4-diol can be determined by detecting the amount of hydrogen taken up during this time. After taking up the stoichiometric hydrogen equivalent to the amount of BYD used, the first reaction stage is completed. Then the temperature in the stirred tank is raised to 130 to 135 ° C and kept until the completion of the hydrogenation to 1,4-butanediol.
• the hydrogenation is carried out at pH values between 4.0 and 9.0.
• Activated nickel catalysts are also known to those skilled in the art as catalysts of the "Raney type", or simply “Raney nickel catalysts” in principle. They are generally made by forming an at least binary metal alloy, mostly comprising aluminum (Al) and nickel (Ni), and then dissolving out aluminum.
• the activated nickel catalysts used in the process according to the invention have a bulk density of not more than 0.8 kg / L, preferably from 0.1 to 0.7 kg / L, more preferably from 0.2 to 0.6 kg / L.
• the activated nickel catalysts used in the process according to the invention contain 65 to 98 wt .-%, preferably 70 to 95 wt .-%, particularly preferably 80 to 90 wt.% Nickel and 0 to 15 wt .-%, preferably 0 to 13 wt.
• nickel catalysts with up to 10 wt.%, Preferably 0.05 to 5 wt.%, Particularly preferably 0.1 to 2 wt.% Molybdenum (Mo) and / or 0 to 10 wt. -%, preferably 0.05 to 5 wt .-%, particularly preferably 1.5 to 3.5 wt .-% of one or more elements selected from the group consisting of iron and chromium used.
• the activated nickel catalysts used in the process according to the invention preferably have an average particle size of not more than 70 mm.
• the optimum particle size is controllable and is matched to the conditions prevailing in the feed reactor.
• the activated nickel catalysts are used as bulk material having a particle size of up to 50 mm, more preferably having a particle size of up to 30 mm and most preferably of not more than 10 mm.
• the average particle size for the particles with a size in the range of 5 microns to 125 mm can be determined by sieve analysis according to DIN 66165.
• an average particle size can be detected optically by means of a microscope, wherein a number average of at least 100 individual values is to be determined.
• the activated nickel catalysts used in the process according to the invention have a BET surface area of 1 to 200 m 2 / g, preferably 10 to 120 m 2 / g, particularly preferably 70 to 100 m 2 / g.
• the specific surface area also called BET surface area, is determined according to DIN 9277 by nitrogen adsorption according to the Brunauer-Emmett-Teller method, as described in US Pat J. Am. Chem. Soc. 1938, Vol. 60, pp. 309-319 ,
• the activated nickel catalysts used in the process according to the invention preferably have a macroscopic foam structure.
• Porous metal foam structures containing many voids may be formed, for example, by the action of gases on a liquefied metal and subsequent cooling.
• Another way to get to such structures is to use organic foam structures as a template (base) for the deposition of a metal and then remove the organic template by combustion.
• the activated nickel catalysts used in the process according to the invention preferably exhibit a porous foam structure, wherein the macroscopic pore sizes in the range of 100 to 5000 .mu.m, preferably from 200 to 2500 .mu.m, more preferably from 400 to 1200 .mu.m exhibit.
• the size of the macroscopic pores can be determined by an optical measurement of the pore diameter of a selected pore. This measurement is repeated for at least 100 different pores, an average value of the pore diameter then calculated as an analysis result.
• Another object of the invention is an activated nickel catalyst having a bulk density of not more than 0.8 kg / L.
• this activated nickel catalyst can be prepared in a process for preparing 1,4-butanediol by hydrogenating 2-butyne-1,4-diol or 4-hydroxybutanal, wherein an aqueous solution containing 2-butyne-1,4-diol or 4- Hydroxybutanal be brought into contact with hydrogen and an activated nickel catalyst, are used.
• the activated nickel catalysts according to the invention have a bulk density of not more than 0.8 kg / L, preferably from 0.1 to 0.7 kg / L, particularly preferably from 0.2 to 0.6 kg / L.
• the activated nickel catalysts according to the invention contain 65 to 98 wt .-%, preferably 70 to 95 wt .-%, particularly preferably 80 to 90 wt.% Nickel and 0 to 15 wt .-%, preferably 0 to 13 wt .-%, especially preferably 4 to 13 wt .-%, most preferably 7 to 13 wt.% Aluminum.
• preferred embodiments of the activated nickel catalyst according to the invention contain up to 10% by weight, preferably 0.05 to 5% by weight, particularly preferably 0.1 to 2% by weight of molybdenum (Mo) and / or 0 to 10% by weight, preferably 0.05 to 5 wt .-%, particularly preferably 1.5 to 3.5 wt .-% of one or more elements selected from the group consisting of iron and chromium.
• Mo molybdenum
• the activated nickel catalysts according to the invention preferably have an average particle size of not more than 70 mm. In principle, the optimum particle size is controllable and is matched to the conditions prevailing in the feed reactor.
• the activated nickel catalysts according to the invention are preferably used as bulk material having a particle size of up to 50 mm, particularly preferably having a particle size of up to 30 mm and very particularly preferably of not more than 10 mm.
• the activated nickel catalysts according to the invention have a BET surface area of 1 to 200 m 2 / g, preferably 10 to 120 m 2 / g, particularly preferably 70 to 100 m 2 / g.
• the activated nickel catalysts according to the invention preferably have a macroscopic foam structure, the macroscopic pores having sizes in the range from 100 to 5000 .mu.m, preferably from 200 to 2500 .mu.m, particularly preferably from 400 to 1200 .mu.m.
• an activated nickel catalyst according to the invention a nickel metal foam is sprayed with an adhesion promoter, coated with aluminum powder and subjected to heat treatment of the material thus obtained. Then, a reduction, singulation and / or shaping of the Ni / Al material obtained after the heat treatment is carried out.
• the activated nickel catalyst according to the invention is obtained therefrom by dissolving out at least part of the aluminum contained therein.
• the nickel metal foam to be used for the preparation of the catalyst of the present invention is preferably used in sheet form having edge lengths of up to 500 mm and a thickness of not more than 5 mm.
• this is first treated with a primer.
• Any primer that improves adhesion between metals and organic materials can be used.
• polyethyleneimine solution is suitable.
• the material After application of the aluminum powder on the nickel metal foam, the material is subjected to a heat treatment in the temperature range of 500 to 1000 ° C., preferably from 600 to 800 ° C, wherein first removes moisture and organic residues from the previous coating process and then at least partially liquefied aluminum and in the nickel foam structure is alloyed.
• the heat treatment is carried out in an atmosphere of oxygen-free inert gas to prevent the formation of interfering oxide layers.
• an aluminum-modified nickel-metal foam is then optionally comminuted, singulated and / or subjected to an appropriate shaping.
• the comminution and separation of the aluminum-modified nickel metal foam can be carried out, for example, by laser cutting or laser beam cutting.
• the resulting pieces of material preferably have a cuboid or parallelepiped shape with a maximum edge length of not more than 50 mm and in their entirety form a bulk material.
• the catalyst according to the invention is obtained by activation of the aluminum-modified nickel foam.
• the aluminum is chemically dissolved out of the material.
• aqueous basic solutions are used, preferably alkali metal hydroxide solutions selected from the group consisting of sodium hydroxide, potassium hydroxide or lithium hydroxide, particularly preferably aqueous sodium hydroxide solution.
• concentration of the aqueous alkali hydroxide solution used in catalyst preparation may generally be between 0.1 and 60% by weight.
• the detachment of the Aluminum also referred to as leaching
• a 5 to 50 wt .-%, more preferably 5 to 35% by weight aqueous sodium hydroxide solution at a temperature of 20 to 100 ° C, preferably at 40 to 85 ° C, more preferably at 50 to 80 ° C.
• the leaching times to be used ie the reaction times of the sodium hydroxide solution with the aluminum-modified nickel metal foam, depend on the aluminum content to be set in the end product, apart from the other reaction conditions mentioned above, and can be between 2 and 240 minutes.
• the activated nickel catalyst according to the invention produced as a result retains the macroscopic foam structure of the nickel foam originally used.
• the at least partial dissolution of the aluminum takes place in near-surface areas, where a highly porous, catalytically active nickel structure is produced.
• the BET surface area of the catalyst according to the invention is preferably greater than that of the nickel metal foam used.
• different dopants and / or promoters can be added. This can be done by alloying a doping metal in the nickel metal foam used for catalyst preparation and / or by wet-chemical aftertreatment of the activated nickel catalyst according to the invention.
• the doping metal may be deposited by precipitation or reductive decomposition of preferably aqueous solution of a suitable precursor.
• one or more doping elements are selected, selected from the group consisting of platinum (Pt), palladium (Pd), rhodium (Rh), ruthenium (Ru), osmium (Os), iridium (Ir), iron (Fe), cobalt (Co), chromium (Cr), molybdenum (Mo), tungsten (Wo), manganese (Mn), rhenium (Re), copper (Cu), silver (Ag) and gold (Au) are used. Particularly preferred are Fe, Co, Cr and / or Mo.
• a commercially available roll paper of nickel foam having a thickness of 1.9 mm, a width of 300 mm and an average pore size of 580 ⁇ m was sprayed with a commercially available primer solution, coated with aluminum powder, and subjected to heat treatment at 700 ° C. After cooling, the material thus obtained was laser cut into square particles having an edge length of 4 mm ⁇ 4 mm and a thickness of 1.9 mm.
• the resulting bulk material was arranged for catalytic activation in a fixed bed of bed and aftertreated by pumping through 5M NaOH solution (sodium hydroxide solution) wet-chemical. A subset A of the bulk material was this wet chemical aftertreatment at 70 ° C for 5 minutes.
• a portion B of the bulk material was post-treated at 60 ° C for 15 minutes with sodium hydroxide solution. Both aliquots were then washed with water until a pH of the wash solution was reached after pumping through the fixed beds ⁇ 10.
• composition of the two catalytically active bulk fractions thus obtained was analyzed by ICP-OES.
• the results are given in the following table: catalyst nickel content aluminum content bulk density A 85.8% by weight 14.1% by weight 0.5 kg / L B 85.3% by weight 14.7% by weight 0.5 kg / L
• Catalyst A was placed in a stirred tank reactor of 500 ml total volume to examine the catalytic activity in the hydrogenation of butyne-1,4-diol (BYD) to 1,4-butanediol (BDO). 300 mL of water were initially introduced into the reactor, and 5 mL of the catalyst A were introduced into a basket positioned near the stirrer shaft below the water level. After closing the reactor, exchanging the atmosphere and filling the reactor with hydrogen up to a pressure of 80 bar, 86.6 g of BYD in 50% aqueous solution were pumped into the reactor with stirring and the reactor was heated to 100.degree.
• BYD butyne-1,4-diol
• BDO 1,4-butanediol
• a catalyst was prepared as described in Example 1, wherein the wet-chemical aftertreatment with 10 wt .-% sodium hydroxide solution was carried out at 60 ° C for a period of 60 minutes.
• the analysis by ICP-OES showed a composition of the resulting catalytically active bulk material (Catalyst C) of 89 wt .-% nickel and 11 wt .-% aluminum.
• Catalyst C was also tested in a stirred tank reactor for its catalytic activity in the hydrogenation of butyne-1,4-diol (BYD) to 1,4-butanediol (BDO).
• BYD butyne-1,4-diol
• BDO 1,4-butanediol
• Catalyst D was used in a pilot fixed bed reactor for the hydrogenation of 4-hydroxybutanal (HBA) to BDO at a temperature of 60 ° C and a hydrogen pressure of 100 bar and showed almost quantitative HBA conversion with very good BDO yields and selectivities to BDO.
• HBA 4-hydroxybutanal
• An activated nickel catalyst of the granule type was produced, as it is known from the prior art, for example DE 2004611 A , is known and used in large-scale conventional equipment for the production of BDO.
• an alloy consisting of 42 wt .-% nickel and 58 wt .-% aluminum was prepared by melting of nickel and aluminum, mechanically comminuted and sieved, so that a grain fraction of 1.8 to 4 mm grain size resulted.
• This alloy granulate fraction was catalytically activated in a fixed bed by pumping through 10 wt .-% sodium hydroxide solution at 60 ° C for 60 minutes and then washed with water until the pH of the resulting wash solution was reached ⁇ 10.
• the aluminum content was about 37% by weight aluminum.
• this prior art catalyst was tested in a stirred tank reactor for its catalytic activity in the hydrogenation of butyne-1,4-diol (BYD) to 1,4-butanediol (BDO).
• BYD butyne-1,4-diol
• BDO 1,4-butanediol
• the resulting amount of nickel saved for a large-scale fixed bed reactor is calculated below using the example of a typical BDO reactor comprising 20 m 3 of catalyst bed.
• a typical BDO reactor comprising 20 m 3 of catalyst bed.
• such an installation is operated on average for at least 8,000 operating hours per year.
• This corresponds to a nickel content of 89 Wt .-% nickel requirement of 5 to nickel compared to a nickel requirement of at least 20.4 tons with granule type catalyst according to the prior art.
• the required amount of nickel can be reduced to 1 ⁇ 4 of the amount customary today, thus providing an extremely efficient process for the preparation of 1,4-butanediol.

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